Method of making outsoles



J. GREGG 7 METHOD OF MAKING OUTSOLES Nov. 7, 1944.

Filed July 5, 1941 4 Sheets-Sheet l 4 Sheets-Sheet 2 ,4 7 roxzA/Ey Nov. 7, 1944. J. GREGG METHOD OF MAKING OU'I'SOLES Filed July 5, 1941 Q 1 MB m N w 5 /,b V TMN 4 MG. wQJ g a Q k M M I I 6 J Nov. 7, 1944.

J. GREGG METHOD OF MAKING OUTSOLES Filed July 5, 1941 4 Sheets-Sheet 4 122. o 124 Q r 1% 12m 121 Z2 Q 1250. m T250. Z3

- INVENTOR. JON GREGG cotton, rayon, nylon" or other synthetic fibers Tlie? turns" or windings or layers of such outsoles 'ings are held together by stitching or by latex,

also absorb and retain considerable moisture and lengthy matter.

is therefore an object of this invention to provide which will absorb some moisture to make the not cup and will not lose its preformed outline or Patented Nov. 7, 1944 '"*"U&ED STATES PATENT OFFICE METHOD OF MAKING QUTSOLES Jon Gregg, Flemington, N. J., assignor to Lynne D. Gregg, Flemington, N. J. 7

Application July 5, 1941, Serial No. 401,179

3 Claims. (Cl. 12-146) This invention relates to outsoles, and methods other desired stripping. With such process, the of making the same. It is particularly directed uncured rubber will make a compact block in the ou oles for footwear, made from bands of curing operation so that the braid or strip will not braided fibrous material or flattened rope, tape or separate. Such an outsole will have breathability elongated strips or ribbons of jute, sisal, manila, because the rubber does not impregnate wholly through the fibers, thus permitting the foot to keep cool and also permitting the sole to be used in a shoe of definite shape and size and-retain this shape and size permanently.

During the curing operation the layers are compressed and the rubber impregnates'into the e in side by side relation with the edges thereof fibers so that the layers become part of the block at the top and bottom of the sole, and have hereand ar not merely attached together, as when tofore been stitched together to rgaln the shapefl ing-l t x dh i of the outsole QIhjd Y 15 Furthermore, such an outsole is not confined The difillillty with 0111580165 wherein the windto any one wind f0 re-shaping as the mgld does the job of giving permanent shape to the outsole. Thus, the shape of the outsole is determined by the mold and not by the thickness or width of or yarn, or animal fibers such as wool or horsehair, either woven or knitted or otherwise formed, or made of cork or leather or other flexible ribbon like material, wound'intothe shape of an outsole. 10

is that such outsoles will not hold their shape, but have a tendency to cup, and the windings tend to separate because the latex adhesive did. .the band.

not have suflicient strength. Furthermore, such Furthermore, such outsoles may be shaped or outsoles often lose their original outline so as not arched by the mold to receive a heel of any type; to have a definite pe a se e e of t e and can also be made with a metal arch molded layers relative to one another in the plane of the into the arch of the sole. Furthermore, suchan outsole -s possible- S outsoles further Will outsole can be made with extra pieces of rubber permit the moisture to penetrate to the foot. Furw t th points where greatest wear is li e y thermore, the drying out of such moisture is a to occur, and a heel can also be molded thereto Such outsoles have formerly during the vulcanizing process. Furthermore, been made mainly of jute because it is the most such a sole can be made with fiber materials absorbent material for latex application and bewhich are easy to dye, whereas, prior methods 1ciaause latex will not stick well to sisal or manila were confined primarily to jute which is difficult l er. to dy Furthermore, since the layers adhered by latex Further, when the outsole is removed from the or stitched together are not under compression, mold, the layersdo not expand to their original not all shapes of outsoles could be obtained bethickness and height, but remain in comp cause the pe depended upon the layers. It form as the blocklike sole has permanent shape.

Yet another object of this invention is to proan outsole of the character described made by vide a highly improved method of making outcoating the fiber, braid, strip, tape or ribbon, with 40 soles, consisting in applying uncured rubber to a crude rubber provided with usual vulcanizing band, winding the bandinto the general shape of agents, or by frictioning in the rubber thereto. a sole, then semi-curing the uncured rub er in before winding the same into the general shape a mold. Footwear can be made with such an of the outsole, and then placing the outsole in a outsole by applying uncured rubber to the top mold and vulcanizing. the rubber by means of surface of said sole and laying an upper thereto, heat and pressure to form an integral, unitary, and then curing the semi-cured rubber in the blocklike outsole which will not go out of shape. sole and the rubber on the top usrface of the and which is of definite shape and light, and sole.

An outsole made in accordance with this invenoutsole non-skid, and quick drying, but which tion, will have exposed portions of fiber at the will not allow the moisture to penetrate through top and bottom of the sole with rubber in between. to the foot. Such an outsole is flexible but will The rubber is harder than the fiber which is above and below the rubber, The fiber serves as an indimensions, and can be made with sisal and sulator of heat and is more comfortable and soft manila or other fibers as well as jute, or of any to step upon, as when a shoe made wi v h a molded thereto at the toe and heel to take up sole is worn on a bare foot. The fiber, it has been found, will mold to the foot, while the rubber gives body and firmness to the sole. Furthermore, the rubber will not hold to a wet surface but the fiber at the bottom of the sole will not slip, and that is an additional advantage of having the fiber extend beyond the rubber on the underside of the sole.

Yet a further object of this invention is to provide an outsole of the character described, made from a fiber strip coated on opposite sides thereof with rubber or having rubber frictione'd into opposite sides thereof and wound continuously from the inside toward the outside of the sole and said sole having at the outside thereof, a second strip with rubber coated or frictioned into the inner side thereof only and forming the outermost turn or convolution in said outsole, so that there is no exposed rubber at the outer edges of said outsole. If desired, the outermost convolution may be made of decorative material; or a shoe upper may be vulcanized directly to the outermost convolution of the sole during the molding operation.

Another object of this invention is to provide a highly improved process of the character described, including the step of pre-shaping the outsole after it is wound and prior to placing the outsole in the vulcanizing mold.

Still a further object of this invention is to provide a highly improved process of the character described, which shall be relatively inexpensive to carry out, and which shall produce a highly efiicient and cheap, durable and practical outsole.

Other objects of this invention will in part be obvious and in part hereinafter be pointed out.

The invention accordingly consists in the features of construction, combinations of elements, and arrangement of parts which will be exemplified in the construction hereinafter described, and of which the scope of application will be indicated in the following claims.

In the accompanying drawings, in which are shown various possible illustrative embodiments of this invention,

Fig. 1 is a top plan view of a winding plate illustrating the method of winding the strip into the shape;

Fig. 2 is a top plan view of an outsole embodying the invention;

Fig. 3 is an enlarged partial view of pieces of braid coated with crude rubber Fig. 4 is an enlarged, cross-sectional view taken on line 44 of Fig. 2, but showing the rubber before the vulcanizing operation;

Fig. 5 is a cross-sectional view similar to Fig. 4, but illustrating the outsole after the molding and vulcanizing operation; s

Fig. 6 is a side elevational view illustrating the method of coating the fiber braid with rubber on both sides;

Fig. 7 is a side elevational view illustrating apparatus for frictioning rubber on one side of a strip of braid;

Fig. 8 is a perspective view illustrating apparatus for frictioning in rubber on opposite sides of a fiber strip;

Fig. 9 is a cross-sectional view illustrating a prior to winding;

. .lfig ll is a top plan view of a vulcanizing mold to give permanentshape to theoiitsole;

Fig. 15 is a cross-sectional view taken on line I5l5 of Fig. 14;

Fig. 16 is a cross-sectional view taken on line Iii-l6 ofFig. 14;

Fig. 17 is a top plan view of a mold embodying the invention, and illustrating a modified construction;

Fig. 18 is a cross-sectional view taken on line |8-I8 of Fig. 17;

Fig. 19 is a top plan view of still another mold embodying the invention, and illustrating another form of the invention;

Fig. 20 is a cross-sectional view taken on line 20-20 of Fig. 19;

Fig. 21 is a cross-sectional view of a mbld for molding an outsole for use with a heel;

Fig. 22 is a top plan view of the mold;

Fig. 23 is a top plan viewof the steel insert for the mold;

Fig. 24 is a view similar to Fig. 21, but showing a shank in the outsole;

Fig. 25 is a top plan view of the outsole in Fig. 24; and

Fig. 26 is a cross-sectional view taken on line 2626 of Fig. 25. Referring now in detail to the drawings, and particularly to Fig. 2 thereof, 10 designates an outsole embodying the invention. Said outsole may be made from an elongated flattened strip of fiber ll wound in a manner hereinafter described, from the inside outwardly with the upper and lower edges of the strip at the top and bottom, and the flat side surfaces of the strip in vertical planes. The strip may be made of braid- ShO n ed fiber cord as shown in Fig. 3, or of flattened rope, as designated by numeral I2 in Fig. 9, or of a tape or ribbon, and may be made of woven or knitted animal or vegetable fiber, such as jute, sisal, manila, cotton, rayon, nylon, wool, horsehair or the like fibers. Cork, leather, composition, or any other flexible ribbon like strips may also be used in making the improved outsole in the manner hereinafter to be described.

The outer end of the strip Il may terminate as at I 5, within an outermost turn or convolution [6 made of a separate strip of the same or different material, such as would serve a a trim for the edge of the sole. The strip l I has rubber on both sides thereof, vulcanized as shown at I! in Fig. 5, whereas, the outermost strip l6 has rubber vulcanized to the inner side thereof only. The ends of the strip [6 overlap, as at 18, as shown in Fig. 2 of the drawings. The vulcanized rubber l1 preferably terminates short of the upper and lower ends of the strip, so as not to be exposed at the top or bottom of, the outsole, as clearly illustrated in Fig. 5 of the drawings.

In making the outsole, crude rubber is coated to opposite side of strips II or l2 and to one side of strip l6 by apparatus 2.0 or 2| shown in Figs. 6 and 11, respectively, or frictioned into said strips by apparatus 23 shown in Fig. 7, or apparatu 24 shown in Fig. 8.

a and 20b between-which the strip I l (or strip should be substantially of the strip l2.

i2) is fed together with a strip 26 of rubber. The rubber strip 26 is thu coated onto one side of the strip. The strip I 2 then passes through another set of calenders c and 20d with a rubber strip 26 fed beneath the fiber strip, so as to coat the opposite side.

In Fig. 11, there is shown apparatus 2| comprising calenders 2laand 21b. The calender 2 lb is formed with a peripheral groove 2 lo into which the rubber strip 26 is fed to be coated onto one side of the fiber strip. If both sides of the strip.

into the groove of the upper calender for a'pplication' to the opposite side of strip l2.

The rubber may be frictioned into the strip l2 insteadof being coated thereon b anpa atvs shown in Fig. 7. The apparatus 250i Fig. comprises a pair of calender 23a, 23b rotat ng in opposite directions. and acalender 23c rotet ing in a direction opposite to the. direction of rotation of the calender 25b. A wad of rubber is fed between the calenders 25a and 23b, he rubber forming a sheet" 50a around calender 2 The strip i2 is fed between the calenders 23b and 25c, so that the rubber 30a. is frictioned int the strip l2. For this purpose. the calenders 23b and 23c must be rotated at different s eeds and the distance between the calenders 23b and 2% The thickness of the rubber strip may be varied by regulating the distances between the calenders 25a.- and 25b. The. width of the rubber strips may be determined by suitable knives adjacent the calenders, as iswell known in the 'art.

In Fig. 8 there is shown apparatus 24 for fr tioning in rubber to opposite ides of s ip "2 The apparatus 24 comprises calenders 24a and 24b rotating in opposite directions and a cale d r 24c rotating in the same direction as calende 24a. A wad of rubber 3i is fed between the, calenders 24a and 24b forming a wide sheet I under another idler roller 58 and again pass s between the calenders 24b and 24c so that the A sheet 3|a of rubber which rolls.

equal to the thickness and has fixed thereto upstanding pins 4|, 42 and 45. I

The strip l2 with rubber on opposite sides thereof starts adjacent pin 4i and then-is wound several turns around pins 4|, 42 spirally and then wound rearwardly about pin 43 and therebeyond and then again back around pin M. The doubled up portion of the strip which is' beyond pin 43 is folded back as shown in Fig. l, and the strip I2 is then wound around pins 4i and 43 several times. The portion of the strip which is disposed around pins 4| and 42 forms the sole portion of the outsole, and the portion around the pin 43 forms the heel portion of the outsole, and the intermediate portion isthe shank portion of the outersole. The winding of the strip on table may be conventional and is well known in the art. However, in accordance with the present invention, the winding terminates one convolution short of the complete outsole, and the outerll, because the crude rubber will flow and increase in width during the vulcanizing process. It is,

of course, understood that the coatingor frictioning in of the rubber is accomplished with the use of crude rubber compounded with the usual vulcanzing agents. When the strips II or i2 and I6 are fully wound, the outsole may be placed in a mold shown in Fig. 12 of the drawings, for pre-shaping. g

The moldcomprises a bottom plate 5i from whi h there extend upwardly dowel pins 52. On

plate 5i is a mold section 53 formed with openings 54 through which the dowel pins pass. Mold section 53 has a cut-out 55 at oneedge thereof conforming to half the longitudinal outline of the outsole.

Extending from mold section 53 are a pair of parallel pins '56.' On plate 5| is the rubber sheet tie is frictioned into an opposite side of the strip i2.

It will be noted that the strip l2 becomes ofiset after it is twisted and thus the portions of the table 451s horizontal and rotates about'its axis strip being first fed between the calenders 24b,

second mold section 51 formed with through openings 58 slidably receiving the pins 56. Mold section 51 has an inner cut-out or edge 59 having the shape of the other longitudinal edge of the sole. Thus, the edges 55 and 59 are complementary and together have the outline of the outsole.

The wound outsole which will be designated by numeral Ilia, before molding, is placed on plate 5! and between the mold sections 53 and 51. Plate 51 may then be pressed towards plate 55 to compress the partly finished outsole Illa for preshapng the same. On plates 53, 51- is a top plate 60 to receive the dowel pins 52. Plate 60 may a so be pressed downwardly to pre-shape the outsole member Illa prior to placing the same in a' mold for the vulcanizing process, This pre-shaping step may be omitted if desired. 1

The outsole Ma with or without the pre-shaping. may then be placed in a mold for a vulcanizing process u er pressure and heat. One

mold for carryin'g f at such vulcanizing process is shown 'in Fig. -14, designated by numeral 65. The mold 65 comprises a bottom plate 66 formed with a recess'or depressed surface 61; At the s de edges of the depressed surface 61 are parallel dove-tailed tongues 68. At the rear of the depressed surface 61 is an edge 10 conforming to outsole.

the contour or outline or half the longitudinal edge of the finished outsole.

Slidably mounted on the depressed surface 61 of plate 66 and between the parallel dove-tailed tongues 68, is a mold section II having dovetailed grooves I2 at the side edges thereof to slidably receive said tongues. The mold section 'II has an edge I3 conforming to the other half of the longitudinal outline of the outsole and is complementary to the edge I0. The outsole Ia is placed beneath the mold edges I0, I3. Mold section II may be pressed toward the edge I0 by means of bell crank levers I5 pivoted to plate 66., as at I6. A top plate I8 may be pressed downwardly against the top of the outsole I0a. Heat may be supplied in any suitable manner. Thus, the heat and pressure causes the rubber on the strips II (or I2) and I6 to vulcanize, forming a block in which the strips are embedded to form a unitar outsole of predetermined and definite shape. The layers of the band are integrated in the block. Said layers are compressed during the molding operation and do not expand again to their natural shape. The rubber flows during the curing to impregnate deeply into the fibers. Thus,

the layers are not only merely adhered together, but, become part of a unitary blocklike outsole. The layers cannot be separated as the band would tear before the rubber would separate under tension.

Attached to the toe portion of edge 13, is a strip spring 13a curved inwardly at its outer end and projecting beyond mold portion II, and adapted to engage the toe portion of edge I0,

to prevent formation of a ridge at the toe of the Similarly. a strip spring 1011, fixed to the heel portion of edge I0, is curved inwardly at its free end and extends beyond edge I0 and engages heel portion of edge 13.

The vulcanized rubber will not be exposed at the top or bottomof the outsole, but will penetrate the windings, so that they cannot separate and the entire outsole I0 formed by the vulcanizing process is in the form of a block of definite shape which will not cup or lose its shape, so that said outsole may be used for making shoes of definite sizes.

The outsole will have breathability because the rubber does not form a complete diaphragm through the middle of the outsole, permitting air to pass through the fibers. Nevertheless, the vulcanized rubber portion I! will be embedded in the fibers and will serve to hold back moisture from passing entirely through the outsole, while permitting absorption at the bottom to make the outsole anti-skid.

In Fig. 17 there is shown a mold 80 embodying the invention and illustrating a modified form thereof. The mold 80 comprises a plate 8| formed with parallel through openings 82, through which extend elongated clamp pins 83. Plate 8| has outwardly extending wings 84, through which the pins 83 pass. The pins 83 have heads 85 contacting the plate 8|. On the pins 83 are coil compression springs 86 contacting the wings 84. Plate 8| has an edge 81 conforming to half the longitudinal edge of the finished outsole, and thus constitutes one mold section.

slidably mounted on the pins 83 is a second plate 90 having wings 9| formed with longitudinal through openings 92, through which the pins pass. Plate 90 has an edge 93 at one-end complementary to the edge 81, and at the other end an edge 94, similar to the edge 81.. On the pins 03 are any suitable number of similar members 90. Between each of the members there is interposed a pair of coil compression springs received on the pins 83.

At the end of the series of intermediate mold plates 90, is an end mold plate 98 having an edge 99 similar to the edge 93. Plate 98 also has through openings I00 through which the pins 83 pass. The pins 83 are formed with screw threaded portions IOI to receive nuts I02 which may be screwed thereon to tighten up all the mold sections. Upon unscrewing the nuts I02, the mold sections 98 and 90 may be slidably moved along the pins 83 to loosen the molds. A bottom plate I05 may be placed beneath all the mold plates.

Each of the plates 90 is provided with upstanding dowel pins 90a, on which there is mounted a top plate I06 which may have a curved forward edge I0I. When the nuts I02 are loosened, all the mold sections are spread apart and the outsoles |0a may be dropped inbetween the complementary sets of edges 81, 93 and 94, 93 and 94, 9,9. Thereafter, the mold plates may be tightened by means of the clamp pins, and pressure applied to the plates I05, I06 and heat also applied for the vulcanizing process.

In Figs. 19 and 20 there is shown a mold IIO illustrating a further modification and comprising a bottom plate III and a plate II2 thereon formed with mold openings 3 for the outlines of the finished outsoles. The bottom plate III may be provided with dowel pins II i passing through openings in plate I,I2.- Plate III may be formed with shallow recesses H8 and I II to receive biscuits of crude rubber located adjacent the toe and heel portions of the outsoles. The outsoles |0a may be dropped into the mold openings II3. A top plate I I5 may then be applied and pressed down which together with heat, will cause the crude rubber biscuits and the crude rubber coatings or rubber frictioned into the wound strip to be vulcanized to the windings.

It will be noted that the outsole I011 is thicker than the finished outsole I0, and is reduced in height or thickness by the pressure during the molding and vulcanizing process.

It will be noted that there is no provision for overflow of rubber in the mold. The outline of the sole is such that it can be dropped into the mold, but is of a height greater than the mold, and the compression of the mold reduces the height of the sole, and as the rubber flows during the curing operation, the rubber penetrates the fibers and does not overflow from the mold.

In Fig. 21 there is shown a mold I20 for molding an arched outsole adapted to receive a heel. The mold I20 may comprise a bottom plate |2I on which is mounted a plate I22 formed with a cut-out I23 having the shape of the finished outsole. Within the opening I23 are complementary mold sections I24 and I25 which may be cut from the block to produce the opening I23. Such block may be sawed longitudinally along the complementary edges I26 to form a two part mold. The outsole I0a may be dropped onto the mold member I24 and then mold member I25 may be applied under pressure and together with heat. This process produces an arched outsole |0b which is lifted at he rear to permit attachment of a heel beneath the heel portion of'the outsole. Platen stops I25a may be screwed to the top of plate I22 to prevent the outsole from being crushed beyond a predetervulcanize such material which may be reinserted into the opening I23 for the molding operation.

During the molding operation, there may be inserted into the outsole, a steel shank I40. The steel shank I40 may have the shape shown in Fig. 25 of the drawings, so as to fit in between the windings of the strip I2. The shank I40 is preferably located half way between the top and bottom of the outsole view. Said steel shank is arched longitudinally as shown in Fig. 24 of the drawings.

If desired, the rubber coated onto or frictioned into the wound strips may be semi-cured instead of being fully vulcanized while the outsole is being molded. Thereafter, the top surface of the outsole may be. coated with uncured rubber and then a usual shoe upper may be laid to the sole;

and the shoe may then be subjected to complete vulcanization by heat alone, to attach the upper to the sole. I

Instead of using uncured rubber, it will be understood that synthetic rubber, such as prene" or plastic compositions, such as Vinylite may be employed, it being a dominant feature of the invention to employ moldable or vulcanizable material to the band, and to then mold or after the band has been wound into the shape of a sole, and to apply pressure during the molding operation to obtain a sole of predetermined shape which will retain its shape after coming out of the mold.

It will thus be seen that ther is provided a device in which the several objects of this invention are achieved, and which is well adapted to meet the conditions of practical use.

As various possible embodiments might be made of the above invention, and as various changes might be made in the embodiments above set forth, it is to be understood that all matter herein Ib', so as to be hidden from set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a, limiting sense.

Having thus described my invention, I claim as new and desire to secure by Letters Patent:

1. A process for making an outsole which compri'ses pressin a preformed strip of thermoplastic material of predetermined dimension and in tacky condition to at least one side of an elongated strip of flexible material of a width substantially equal to the thickness of the outsole and greater than the width of said strip of thermoplastic material, so that said strip of thermoplastic material is positioned between and spaced from the edges of said strip of flexible material,

winding the laminated strips so formed into the shape of an outsole, and applying heat and pressure to said outsole so as to cause said thermoplastic material to soften and unite the convolutions of said strips.

2. A process of making an outsole, consisting in forming an elongated strip of vulcanizable material in tacky condition, then pressing said strip to a side of an elongated strip of flexible material of a width equal to the thickness of the sole to be made, to cause the first strip to stick to the strip of flexible material, then winding said strips to form the general shape or an outsole, and then semi-curing the curable material.

3. Process for making an outsole which comprises pressing a preformed strip of vulcanizable material of predetermined dimension and in tacky condition to at least one side of an elongated flat strip of flexible material of a width substantially equal to the thickness of the outsole and greater than the width of said strip 01' vulcanizable material, so that said strip of vulcanizable material is positioned between and spaced from the edges of said strip of flexible material, winding the laminated strip so formed into the shape of an outsole, and applying heat and pressure to said outsole so as to cause the'vulcanization or said vulcanizable material and to unite said strips.

JON GREGG. 

